Battery pack of electric vehicle, electric vehicle chassis and method for replacing battery modules

ABSTRACT

Provided are systems and methods for configuring battery packs in electric vehicles. A battery pack may include a plurality of battery modules, a support part, and at least one opening provided on the support part. The support part may be provided with a bottom for supporting the plurality of battery modules, sides, a top, and an accommodation space formed by the bottom, the sides, and the top for accommodating the plurality of battery modules. The opening provided on the bottom of the support part may enable the plurality of battery modules to be passed through the at least one opening and be detachably mounted to the bottom of the support part so as to be supported by the bottom.

CROSS-REFERENCES TO RELATED APPLICATIONS

The present application is a divisional of U.S. NonprovisionalApplication No. 15/425,118, filed Feb. 6, 2017, which is a continuationof U.S. Nonprovisional Application No. 15/006,126, filed Jan. 26, 2016,which claims the benefit of an priority to U.S. Provisional ApplicationNo. 62/273,995, filed Dec. 31, 2015, and U.S. Provisional ApplicationNo. 62/150,848, filed Apr. 22, 2015, and U.S. Provisional ApplicationNo. 62/133,991, filed Mar. 16, 2015, the entire disclosures of each ofwhich are hereby incorporated by reference for all purposes.

BACKGROUND OF THE INVENTION

The present disclosure relates to the field of electric vehicles, andparticularly relates to battery pack structures of electric vehicles,electric vehicle chassis with battery packs and methods for removing andreplacing battery modules from electric vehicle chassis.

Serving as a primary energy source, a battery pack is one of the mostimportant components of the electric vehicle. The battery pack isusually formed by combination of a plurality of battery modules. Duringoperation of an electric vehicle, some of the plurality of batterymodules may malfunction. However, because battery modules in batterypacks are usually mounted as an integral structure, in the case ofmalfunction of a single battery module, the malfunctioned battery modulecannot be separately removed and replaced.

BRIEF SUMMARY OF THE INVENTION

Provided are systems and methods for configuring battery packs inelectric vehicles. In one aspect of the present disclosure, a batterypack for an electric vehicle is provided. The battery pack may include aplurality of battery modules. The battery pack may also include asupport part provided with a bottom for supporting the plurality ofbattery modules, sides, a top, and an accommodation space formed by thebottom, the sides, and the top for accommodating the plurality ofbattery modules. The battery pack may further include at least oneopening provided on either the bottom or sides of the support part toenable the plurality of battery modules to be passed through the atleast one opening and be detachably mounted to either the bottom orsides of the support part so as to be supported by either the bottom orsides.

In some embodiments, the battery pack may further include a layermounted above the top of the support part to cover the plurality ofbattery modules accommodated in the support part. In some embodiments,the at least one opening is provided on the bottom of the support part.In some embodiments, the battery pack may further comprise first andsecond mounting flanges provided on each of the plurality of batterymodules. The first and second mounting flanges may be respectivelyarranged on two opposite sides of a bottom of each of the plurality ofbattery modules so that the plurality of battery modules can be mountedto the bottom of the support part using the first and second mountingflanges. The first and second mounting flanges may be mounted below thebottom of the support part.

In some embodiments, the plurality of battery modules may be mounted tothe bottom of the support part through fasteners. In some embodiments,the battery pack may further comprise a protector sheet mounted belowthe bottom of the support part to cover the plurality of battery modulesaccommodated in the support part. In some embodiments, the layer mountedabove the top of the support part is a carbon fiber composite layer.

In another aspect of the present disclosure, an electric vehicle chassisis provided. The electric vehicle chassis may include an underbody panellocated below a cabin of an electric vehicle. The electric vehiclechassis may also include two side sills extending along the longitudinaldirection of the underbody panel. Each of the two side sills may includean upper part and a lower part and may be connected to one of the twoopposite sides of the underbody panel through the upper part thereof.The electric vehicle chassis may further include a battery pack locatedbelow the underbody panel and between the two side sills. The batterypack may be configured to be mounted to the lower parts of the two sidesills through the bottom of the support part.

In some embodiments, the electric vehicle chassis may further include alayer mounted above the top of the support part to cover the pluralityof battery modules accommodated in the support part. In someembodiments, the at least one opening provided on the support part isprovided on the bottom of the support part. In some embodiments, thebottom of the support part is provided with mounting flanges extendingalong the longitudinal direction of the underbody panel, and the batterypack may be mounted to the lower parts of the two side sills using themounting flanges. In some embodiments, the mounting flanges of thesupport part are mounted to the lower parts of the two side sillsthrough fasteners.

In some embodiments, the electric vehicle chassis may further includefirst and second mounting flanges provided on each of the plurality ofbattery modules. The first and second mounting flanges may berespectively arranged on two opposite sides of a bottom of each of theplurality of battery modules so that the plurality of battery modulescan be mounted to the bottom of the support part using the first andsecond mounting flanges. The first and second mounting flanges may bemounted below the bottom of the support part.

In some embodiments, the plurality of battery modules are mounted to thebottom of the support part through fasteners. In some embodiments, theelectric vehicle chassis may further include a protector sheet mountedbelow the bottom of the support part to cover the plurality of batterymodules accommodated in the support part. In some embodiments, the layermounted above the top of the support part is a carbon fiber compositelayer.

In another aspect of the present disclosure, a method for replacing abattery module in an electric vehicle is provided. The method mayinclude identifying a first battery module from among a plurality ofbattery modules in a battery pack. The method may also include detachingthe first battery module from the bottom of the support part. The methodmay further include removing the first battery module from the supportpart by passing the first battery module through the at least oneopening. In addition, the method may include inserting a second batterymodule into the support part by passing the second battery modulethrough the at least one opening and mounting the second battery moduleto the bottom of the support part.

In some embodiments, the second battery module may have a higherelectrical potential energy than the first battery module. In someembodiments, the method may further include removing a protector sheetfrom below the bottom of the support part. In some embodiments, themethod may also include removing fasteners that are configured to mountthe first battery module to the bottom of the support part.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates a schematic sectional view showing the mounting of abattery module to a battery pack according to a first example of thepresent disclosure.

FIG. 2 illustrates a perspective schematic view showing a support partof the battery pack according to a first example of the presentdisclosure.

FIG. 3 illustrates a perspective schematic view showing a battery moduleaccording to an exemplary embodiment of the present disclosure.

FIG. 4 illustrates an exploded schematic sectional view of an electricvehicle chassis including a battery back according to a first example ofthe present disclosure.

FIG. 5 illustrates a schematic structural sectional view of the electricvehicle chassis including a battery back according to a first exam pieof the present disclosure.

FIG. 6 illustrates a schematic sectional view showing the removal of abattery module from the electric vehicle chassis including the batteryback according to a first example of the present disclosure.

FIG. 7 illustrates a schematic sectional view showing a battery packaccording to a second example of the present disclosure.

FIG. 8 illustrates a schematic sectional view showing the removal of abattery module from the electric vehicle chassis including the batteryback according to a second example of the present disclosure.

FIG. 9 illustrates a schematic sectional view showing the removal of abattery module from the electric vehicle chassis including the batteryback according to a second example of the present disclosure.

DETAILED DESCRIPTION OF THE INVENTION

The present disclosure provides systems and methods that overcome thelimitations of current battery packs employed in electric vehicles. Thepresent disclosure is intended to provide a battery pack with batterymodules convenient to be replaced, and a method for removing and/orreplacing the battery modules from an electric vehicle chassis. Comparedto currently available battery packs, battery packs provided by thepresent disclosure have several advantages, which include: battery packsof the present disclosure are provided with a support part, each batterymodule can be separately mounted in the support part through an openingprovided in the bottom or side of the support part, and due to thismodular installation manner, the battery modules can be separatelydisassembled and replaced from the battery pack, so that the replacementis convenient, a large amount of tedious and complex disassembly work isavoided, and the cost is reduced.

FIG. 1 illustrates a schematic sectional view showing the mounting of abattery module 103 to a battery pack 101 according to a first example ofthe present disclosure, which is cut perpendicular to the longitudinaldirection of the battery pack. As shown in FIG. 1, the battery pack 101of an electric vehicle may include a plurality of battery modules 103and a support part 102, and the plurality of battery modules 103 may bemounted in the support part 102.

FIG. 2 illustrates a perspective schematic view showing the support part102 of the battery pack 101 according to the first example of thepresent disclosure. The longitudinal direction (as shown by the arrow Ain FIG. 2) of the support part 102 is parallel with the longitudinaldirection of the battery pack 101. As shown in FIG. 2, in someembodiments the support part 102 is provided with a bottom 401, a top402 and four sides 403. The bottom 401, the top 402 and the sides 403together form an accommodation space 405. The bottom 401 may include aplurality of openings 404, each of which may have a width Dl in thedirection perpendicular to the longitudinal direction of the supportpart 102. The sides 403 can be formed by a plurality of columnsextending upwards from the bottom 401. The top 402 may be located abovethe sides 403 and may be formed with a frame structure, such as withfour edges connected together.

In some embodiments, the battery modules 103 may be passed through theopenings 404 from the underside of the bottom 401 into the accommodationspace 405. The support part 102 shown in FIG. 2 includes two openingsalong the width direction of the support part 102 (perpendicular to thelongitudinal direction of the support part 102), and as such, thesupport part 102 may accommodate two rows of battery modules 103 as seenalong the longitudinal direction of the support part 102. In someembodiments, the support part 102 may accommodate more than two rows ofbattery modules 103. The support part 102 is usually made from alightweight high-strength material, such as aluminum alloy, magnesiumalloy and any other lightweight high-strength material.

In some embodiments, the support part 102 may only be provided with thebottom 401, but may lack the top 402 and the sides 403. However, the top402 and the sides 403 may make the support part 102 more stable. In someembodiments, the bottom 401, the top 402 and the sides 403 may also bemade from plate like materials. However, the frame structures as shownin FIG. 2 may reduce the weight of the support part.

FIG. 3 illustrates a perspective schematic view showing a battery module103 according to an exemplary embodiment of the present disclosure. Abattery module may provide electrical energy to power an electric motorlocated within an electric vehicle. During vehicle operation, a givenbattery module may lose electrical potential energy, or voltage, and mayneed to be replaced. The manner in which one battery module loseselectrical potential energy during vehicle operation may differ and beindependent from how another battery module loses electrical potentialenergy.

As shown in FIG. 3, each battery module 103 may be provided with a firstmounting flange 501 and a second mounting flange 502 on opposite sidesof a bottom of the body thereof In some embodiments, the body of eachbattery module 103 is a width D2, and the distance between the outeredges of the first mounting flange 501 and the second mounting flange502 along the longitudinal direction thereof is D3. In some embodiments,the width D1 of each opening 404 in the bottom 401 of the support part102 is greater than the width D2 of the body of each battery module 103,and is smaller than the distance D3 between the outer edges of the firstmounting flange 501 and the second mounting flange 502 along thelongitudinal direction thereof. In mounting a battery module 103 to thesupport part 102, the battery module 103 is arranged such that thelongitudinal direction of the first mounting flange 501 and the secondmounting flange 502 thereof is parallel with the longitudinal directionof the support part 102, and as such, the body of the battery module 103is able to pass through the opening 404 from the underside of theopening 404 while the first mounting flange 501 and the second mountingflange 502 of the battery module 103 are unable to pass through theopening 404. Accordingly, the battery module 103 can be mounted to thebottom 401 of the support part 102 through the first mounting flange 501and the second mounting flange 502. A shown in FIG. 1, after the batterymodule 103 is mounted to the bottom 401 of the support part 102, thefirst mounting flange 501 and the second mounting flange 502 are locatedbelow the bottom 401 of the support part 102.

As shown in FIG. 1, the battery pack 101 may also comprise a carbonfiber composite layer 104 and a protector sheet 105. The carbon fibercomposite layer 104 may be mounted above the top 402 of the support part102 to cover the plurality of battery modules 103 accommodated in thesupport part 102. The carbon fiber composite layer 104 is usually madefrom a refractory material for isolating heat and playing a role ofshielding EMI (Electro-Magnetic Interference), however other materialsmay also be suitable. The protector sheet 105 is mounted below thebottom 401 of the support part 102 to cover the plurality of batterymodules 103 accommodated in the support part 102. The protector sheet105 is usually made from a high-strength material (such as titaniumalloy, steel and so on) for protecting the battery modules 103.

As shown in FIG. 3, the first mounting flange 501 and the secondmounting flange 502 of the battery module 103 may be provided withmounting holes 503 and as shown in FIG. 2, the bottom 401 of the supportpart 102 is provided with a plurality of mounting holes 406. Thus, asshown in FIG. 1, the battery modules 103 can be mounted to the bottom401 of the support part 102 via first fasteners 107 which match themounting holes. In addition, as shown in FIG. 1, the carbon fibercomposite layer 104 and the protector sheet 105 may be mounted to thesupport part 102 via second fasteners 106 and third fasteners 108,respectively. To this end, as shown in FIG.

2, the top 402 and bottom 401 of the support part 102 are provided withmounting holes for mounting the carbon fiber composite layer 104 and theprotector sheet 105. It should be understood that the battery modules103, the carbon fiber composite layer 104 and the protector sheet 105can be mounted using other methods other than using fasteners.

An assembly process of the battery pack 101 will now be described belowwith reference to FIG. 1, FIG. 2 and FIG. 3. In some embodiments, thefirst step may comprise mounting the battery modules 103 to the supportpart 102. Specifically, the first step may comprise arranging a batterymodule 102 such that the longitudinal direction of the first mountingflange 501 and the second mounting flange 502 of the battery module 103is parallel with the longitudinal direction of the support part 102. Thesecond step may comprise passing the body of the battery module 103through an opening 404 in the bottom 401 of the support part 102 fromthe underside of the opening 404 and aligning the mounting holes 503 inthe first mounting flange 501 and the second mounting flange 502 of thebattery modules 103 with the corresponding mounting holes 406 in thebottom 401 of the support part 102. The third step may compriseinserting the first fasteners 107 through the mounting holes andfastening the first fasteners 107. Thus, following these steps, thebattery module 103 may be mounted to the support part 102 and otherbattery modules may be mounted in the same way as described.

After the plurality battery modules 103 are mounted to the support part102, the fourth step may comprise mounting the carbon fiber compositelayer 104 and the protector sheet 105 to the support part 102.Specifically, the fourth step may comprise mounting the carbon fibercomposite layer 104 above the top 402 of the support part 102 throughthe second fasteners 106 and mounting the protector sheet 105 below thebottom 401 of the support part 102 through the third fasteners 108. Itshould be understood that the assembly process of the battery packaccording to the first example of the present disclosure is not limitedto the sequence as described above. For example, the carbon fibercomposite layer 104 can be mounted above the top 402 of the support part102 before the plurality battery modules 103 are mounted to the supportpart 102.

It can be seen from the above description that the battery modules 103in the present disclosure may be mounted in the battery pack 101 in amodularized manner. Thus, the plurality of battery modules 103 may beadded and/or removed separately from one another. The carbon fibercomposite layer 104 and the protector sheet 105 may be mountedindependently from each other and from the battery modules and thereforecan be removed separately.

In some embodiments, the battery pack according to the presentdisclosure constitutes a part of an electric vehicle chassis. FIG. 4illustrates an exploded schematic sectional view of an electric vehiclechassis including the battery back 101 according to the first example ofthe present disclosure. FIG. 5 illustrates a schematic structuralsectional view of the electric vehicle chassis including a battery backaccording to the first example of the present disclosure. As shown inFIG. 4 and FIG. 5, in some embodiments, the electric vehicle chassis 300includes an underbody panel 301, two side sills 302 and a battery pack101 . The underbody panel 301 is located below a cabin (not shown) of anelectric vehicle. The two side sills 302 may extend along thelongitudinal direction of the underbody panel 301. Each of the two sidesills 302 may include an upper pan 3021 and a lower part 3022 and may beconnected to one of the two opposite sides of the underbody panel 301through the upper part 3021. The battery pack 101 may be located belowthe underbody panel 301 and may be located between the two side sills302, and the battery pack 101 may be mounted to the lower parts 3022 ofthe side sills 302. In some embodiments, the longitudinal direction ofthe battery pack 101 is parallel with the longitudinal direction of theunderbody panel 301.

To enable the battery pack 101 to be mounted to the lower parts 3022 ofthe side sills 302, the battery pack 101 according to the first exampleof the present disclosure may be provided with a first mounting flange4011 and a second mounting flange 4012 on the opposite sides of thebottom 401 of the support part 102. The longitudinal direction of thefirst mounting flange 4011 and the second mounting flange 4012 may beparallel with the longitudinal direction of the battery pack 101. Eachof the two side sills 302 may be provided with mounting holes 304 at thelower part 3022 thereof, and the first mounting flange 4011 and thesecond mounting flange 4012 of the support part 102 may also be providedwith corresponding mounting holes such that the battery pack 101 can bemounted to the lower parts 3022 of the two side sills 302 via fourthfasteners 303 which match the mounting holes. It should be understoodthat since the first mounting flange 501 and the second mounting flange502 of the battery module 103 are located below the bottom 401 of thesupport part 102, to mount the bottom 401 of the support part 102 to thelower parts 3022 of the two side sills 302, the first mounting flange501 and the second mounting flange 502 of the battery module 103 canalso be provided with mounting holes for the fourth fasteners. However,the first mounting flange 501 and the second mounting flange 502 of thebattery module 103 may lack the mounting holes for the fourth fasteners,provided that the width of the first mounting flange 4011 and the secondmounting flange 4012 of the support part 102 are set greater than thewidth of the first mounting flange 501 and the second mounting flange502 of the battery module 103.

Since the battery pack 101 according to the present embodiment aremodularly mounted, in the case of malfunction of a battery module 103,the malfunctioned battery module 103 can be easily removed and replaced.The removal process of the battery modules 103 will be described below.

FIG. 6 illustrates a schematic sectional view showing the removal of abattery module from the electric vehicle chassis including the batteryback according to the first example of the present disclosure. As shownin FIG. 6, when a battery module 103 malfunctions and is to be replaced,the first step may be to identify the malfunctioned battery module thatneeds to be replaced due to one of several possible reasons, includinglow electrical potential energy The next step may be to remove the thirdfasteners 108 from the underside of the electric vehicle chassis 300 sothat the protector sheet 105 can be removed from the support part 102.Next, the first fasteners 107 used by the malfunctioned battery module103 are removed to allow removal of the malfunctioned battery module 103from the underside of the support part 102. The process of mounting areplacement battery module 103 in the battery pack 101 is the reverse ofthe foregoing removal process, and will not be repeated herein.

The first fasteners 107, the second fasteners 106, the third fasteners108 and the fourth fasteners 303 as mentioned above may be anydetachable parts and components used for fastening in the prior art, forexample, a bolt different fasteners can be used for connecting differentcomponents to facilitate removing of the components.

By means of the structures of the battery pack according to the firstexample of the present disclosure and the electric vehicle chassisincluding the battery pack, and the method of removing a battery modulefrom an electric vehicle chassis including a battery pack according tothe first example of the present disclosure, a malfunctioned batterymodule 103 can be removed from the electric vehicle chassis from theunderside of the chassis separately without influencing other batterymodules 103. The battery pack 101 also does not need to be entirelyremoved, and therefore any malfunctioned battery module 103 can bereplaced conveniently through the present disclosure.

FIG. 7 illustrates a schematic sectional view showing a battery packaccording to a second example of the present disclosure, in which thearrow shows the mounting direction of the battery module. The structureof the battery pack 101′ according to the second example is generallysimilar to that in the first example, with one difference being in thatin the first example the battery module 103 is generally detachablymounted in the accommodation space 405 via passing through the bottom401 of the support part 102 of the battery pack 101. In the secondexample, a battery module 103′ is generally detachably mounted in theaccommodation space 405′ via passing through the sides 403′ of thesupport part 102′ of the battery pack 101′.

Specifically, a plurality of openings are provided in the two sides 403′in the longitudinal direction of the support part 102′, so that aplurality of battery modules 103′ can pass through the plurality ofopenings to enter the accommodation space 405′ and are detachablymounted at the bottom 401′ of the support part 102′. Therefore, when thebattery pack 101′ is assembled, the battery modules 103′ may be passedthrough the openings from the sides of the openings in the sides 403′ ofthe support part 102′ to enter the accommodation space 405′, and thenthe plurality of battery modules 103′ may be detachably mounted at thebottom 401′ of the support part 102′ through the second fasteners 107′.It should be noted that, unlike the first example, according to thesecond example, the first mounting flange 501′ and the second mountingflange 502′ of the battery modules 103′ may be located above the bottom401′ of the support part 102′.

Since the battery modules 103′ enter the accommodation space 405′ fromthe openings in the sides 403′, there may be no need to remove theprotector sheet 105′ when removing a malfunctioned battery module 103′from the battery modules 103′. Therefore, in the second example, thestep of mounting the protector sheet 105′ below the bottom 401′ of thesupport part 102′ through the third fasteners 108′ may be prior to orafter the step of mounting the battery modules 103′ on the support part102′. The manner of mounting the battery pack 101′ according to thesecond example on the electric vehicle chassis 300′ is the same as thataccording to the first example, and will not be repeated herein.

FIGS. 8 and 9 illustrate schematic sectional views showing the removalof a battery module from the electric vehicle chassis including thebattery back according to the second example of the present disclosure.As shown in FIG. 8, the passage for removing a malfunctioned batterymodule 103′ is formed by directly removing a corresponding side sill302′.

As shown in FIG. 9, each side sill 302′ of the electric vehicle chassisincluding the battery pack 101′ according to the second example isprovided with at least one detachable part 901′. A passage 902′ forremoving the malfunctioned battery module 103′ is formed by removing thedetachable part 901′.The size of the detachable part 901′ may meet therequirement that the battery modules 103′ be able to pass through thepassage 902′ formed by removing the detachable part 901′ withoutinfluencing the supporting strength of the side sills 302′. The locationof the detachable part 901′ may meet the requirement that the connectionand fixation of the side sill 302′ with other components is notsignificantly influenced.

It should be noted that according to different design requirements of anelectric vehicle chassis, the battery pack 101′ may be first removedfrom the electric vehicle chassis 300′. Then, the malfunctioned batterymodule 103′ may be removed from the battery pack 101′ and replaced witha new battery module 103′.

The technical features in the embodiments described above can berandomly combined. The foregoing descriptions are embodiments andaccompanying drawings of the present disclosure, and arc not used forlimiting the scope of protection of the present disclosure. Any contentimplemented by the same technical means or encompassed in the scope ofprotection of the contents of the claims below do not depart from thescope of the present disclosure, but fall into the scope of protectionof the applicant.

What is claimed is:
 1. A method for replacing a battery module in anelectric vehicle, the method comprising: identifying a first batterymodule from among a plurality of battery modules in a battery pack,wherein the battery pack is located within the electric vehicle andcomprises: the plurality of battery modules; a support part forsupporting the plurality of battery modules, wherein at least oneopening provided on either a bottom or a side of the support part suchthat at least one of the plurality battery modules can pass through theat least one opening and be detachably mounted to either the bottom orthe side of the support part; a layer mounted above the top of thesupport part to cover the plurality of battery modules; and a protectorsheet mounted below the bottom of the support part to cover theplurality of battery modules; detaching the first battery module fromthe bottom of the support part; removing the first battery module fromthe support part by passing the first battery module through the atleast one opening; inserting a second battery module into the supportpart by passing the second battery module through the at least oneopening; and mounting the second battery module to the bottom of thesupport part.
 2. The method of claim 1 wherein the second battery modulehas a higher electrical potential energy than the first battery module.3. The method of claim 2, further comprising: removing a protector sheetfrom below the bottom of the support part.
 4. The method of claim 2,further comprising: removing fasteners that are configured to mount thefirst battery module to the bottom of the support part.